The purpose of this study is to optimize the composition of CSA (calcium sulfoaluminate) cement with sodium silicate (Na₂SiO₃) and gypsum for binder jetting 3D printing. The preliminary test was carried out with an applicator to decide the proper thickness of one layer before using the 3D printer. A liquid binder was then selected to maintain the shape of the particles. Based on the results, the optimal mixture of dry materials and a liquid activator was derived through various parametric studies. For dry materials, the optimum composition of CSA cement, gypsum, and sand was suggested, and the liquid activator made with sodium silicate solution and VMA (viscosity modified agent) were selected. The setting time with gypsum and sodium silicate was controlled within 30 s. In case of the delayed setting time and the rapid setting mixture, the jetting line was printed thicker or thinner and the accuracy of the printout was degraded. In order to adjust the viscosity of the liquid activator, 10% of the VMA was used in 35% of sodium silicate solution and the viscosity of 200–400 cP was suitable to be sprayed from the nozzle. With this optimal mixture, a prototype of atypical decorative wall was printed, and the compressive strength was measured at about 7 MPa.

Conventional formwork systems are limited in their ability to efficiently realize complex and free-form concrete geometries, while additive manufacturing (AM)-based formwork faces constraints in casting-stage structural stability and cost-effectiveness, particularly at construction scale. To address these limitations, a hybrid formwork system integrating a structural steel frame with 3D-printed modules is proposed, in which the steel frame resists casting-induced lateral pressure while the printed components define complex mold geometries. The system was fabricated and validated through a full-scale case study structure measuring 3.0 m × 1.7 m × 2.2 m, produced using a large-scale fused deposition modeling (FDM) process with carbon-fiber-reinforced ABS (ABS-CF20). Geometric accuracy was evaluated by comparing design dimensions with as-built measurements across planar, edge, curved, and inclined regions. Construction efficiency and cost performance were assessed through process-based and cost-based comparisons with conventional steel formwork and fully 3D-printed formwork alternatives. The constructed structure reproduced the intended geometry with an average deviation of approximately 3.2 mm and a maximum deviation within ±4 mm, and no notable formwork deformation or damage was observed during concrete casting. Relative to conventional steel formwork, the hybrid system reduced total fabrication duration by about 50% and fabrication cost by about 60% based on a normalized cost index, while also outperforming fully 3D-printed formwork in cost efficiency by about 45%. The modular configuration and bolted connection system further improved transportability, on-site assembly efficiency, and component reusability. These findings demonstrate that the proposed hybrid formwork system provides a practical and resource-efficient pathway for fabricating complex concrete structures, supporting the broader adoption of digital fabrication in sustainable construction practice.